(navigation image)
Home American Libraries | Canadian Libraries | Universal Library | Community Texts | Project Gutenberg | Children's Library | Biodiversity Heritage Library | Additional Collections
Search: Advanced Search
Anonymous User (login or join us)
Upload
See other formats

Full text of "John_Deere_Riding_Mower_55_56"

SLIDE TEXT 
ST 55-56 



CONSUMER PRODUCTS 



r* 



55 and 56 



RIDING MOWER 




SECTION 10 
GENERAL 1 



r^ 



INTRODUCTION: 

New for 19 70 are the 55 and 56 JOHN 
DEERE Riding Mowers. These riding Mow- 
ers have been developed and tested to 
the high standard of JOHN DEERE quality. 
We feel that these two riders will make 
a valuable addition to our line of Con- 
sumer Products . 

The 55 is a 5 horsepower rider with a 
26-inch mower. The 56 is a 6 horsepower 
rider with a 28-inch mower and has an 
electric start option available. 

There are many like features as well as 
distinguishing features between the 55 
and 56 riders. This service text will 
cover both models. Where differences 
occur in the service procedure, it will 
be so noted and shown in this text. 



RM GEN 1 




SPECIFICATIONS: 

Wheel Tread 

Front 55 & 56 22 in. 

Rear 55 & 56 22 in. 

Tire Sizes 

Front 55 10.50x3.50 

Semi-pneumatic 

56 11x4.00 - 5 

Rear 55 & 56 4.00x4.80 - 8 

Tire Inflation 

Front 55 Semi-pneumatic 

56 8 lbs. 

Rear 55 & 56 12 lbs. 



1 - 



SECTION 10 
GENERAL 2 



DIMENSIONS: 

Wheel Base 55 & 56 40 in. 

Over-all Length 55 & 56 54 in. 

Over-all Height 55 36.5 in. 

56 37.5 in. 

Over-all Width 55 34.5 i n . 



56 



Turns Outside 55 & 56 



Weight (including mower) 55 

56 



36.5 in. 
30 in. 

250 lbs. 
260 lbs. 



Width of Cut 55 26 in. 

56 28 in. 

Height of Cut 55 & 56 1-3 i n . 

********************* 

PREDELIVERY : 



RM GEN 2 



The rider mowers will be shipped with- 
out the front wheels assembled. 

Assemble the front wheels to the riders 
by placing wheel, washer and snap ring 
on spindle as shown. 

On 56 Riders, install plastic cap over 
wheel hub. 

Grease the wheel with SAE approved 
multi-purpose grease. 




Position front wheels straight forward. 
Remove steering wheel or handle bars and 
spring pin from steering shaft. Place 
flat washer over steering shaft and po- 
sition steering wheel or handle bars 
upright on shaft. Insert pin through 
hub and steering shaft. 



********************* 

RM GEN 3 



********************* 




-2- 



SECTION 10 
GENERAL 3 



LUBRICATION: 

Check lubrication and if necessary lubri- 
cate (6) areas shown with SAE multi-purpose 
grease. Lubricate every 10 hours of opera- 
tion. 



RM GEN 4 




************** 




Check the engine oil level. When full, 
oil will be at the top of the plug hole. 
Add AM 30730 (SAE 30) oil if necessary. 

Use AM 30730 (SAE 30) oil in Summer and 
AM 30 710 (SAE 10) oil in Winter. 



RM GEN 5 




********************* 



CUSTOMER DELIVERY: 

Be sure the customer has his operator's 
manual and encourage him to read it. 

Explain mower operation and safety fea- 
tures. Advise the customer to change 
oil after the first two hours of opera- 
tion. This will remove any abrasive par- 
ticles, which may appear after the first 
few hours of operation. 

Remember: Not all customers will read 
their operator's manuals. The time you 
spend explaining the mower service and 
operation is most important. 



RM GEN 6 





r\Mfr> 





********************* 



SECTION 20 
ENGINE 1 



ENGINE SPECIFICATIONS: 






55 



56 



Manufacturer Tecumseh Tecumseh 

Mode l V 50 V60 

Cylinder Single, C.I. sleeve Single, C.I. sleeve 

Bore and Stroke 2.63 x 2.25 in 2.63 x 2.50 in. 

Displacement 12.176 cu. in 13.53 cu. in. 

T yP e 4-cycle, vertical crankshaft 4-cycle, vertical crankshaft 

Speeds (fast) 1800-3600 rpm 1800-3600 rpm 

Speeds (idle) 1200-1700 rpm 1200-1700 rpm 

Horsepower 5 HP @ 3600 rpm 6 HP @ 3600 rpm 

Valve Clearance (intake) cold 0.010 in 0.010 in. 

Valve Clearance (exhaust) cold 0.010 in 0.010 in. 

Compression Release. Internal mechanical type Internal mechanical type 

Cranlcase Capacity 1-1/2 U.S. pints 1-1/2 U.S. pints 

Type of Crankcase 

Lubricant AM 30730 Summer AM 30730 Summer 

AM 30710 Winter AM 30710 Winter 

Starter R ope recoil Rope recoil 



We cannot over-stress the importance 
of a clean air filter. Tap filter 
lightly to remove dirt. Never use com- 
pressed air or a liquid cleaner of any 
type to clean filter as these may damage 
air filter and result in damage to the 
engine. Replace filter every 100 hours 
of service or sooner if it becomes ex- 
tremely dirty. 

Shown is a vibrating tachometer available 
from Tecumseh (part no. 670156, price 
$3.95) which will enable you to set the 
engine speed accurately. 



70 ENG 1 




******** 



************ 



The serial number plate for the engine 
contains several groups of numbers. The 
serial number of the engine is the num- 
ber which immediately follows the word 
serial on the serial plate. This number 
is valuable to the factory and should 
appear on warranty claims and correspon- 
dence referring to engine problems . 



70 ENG 2 




***************** **** 

- 4- 



r- 



r^ 



SECTION 20 
ENGINE 2 



SERVICE TOOLS: 

Shown are the service tools required for 
2-7 HP Tecumseh engines. They are from 
left to right: 



70 ENG 3 



1. 
2. 
3. 
4, 
5. 
6. 



Flywheel Knock-off Nut. 

(Tecumseh 670169) 
Oil Seal Driver Adapter. 

(Tecumseh 2 86 7 7 A) 
Seal Seat Tools. 

(Tecumseh 2 86 7 7 A) 
Bearing Tool. 

(Tecumseh 28678) 
Oil Sleeve Tools. 

(Tecumseh 28676) 
Flywheel Puller. 

(OTC 915A) 




********************* 



Torque cylinder head bolts to 140-200 
in. lbs. in the sequence shown to assure 
uniform seating of the head and head gas- 
ket. For other torque values refer to 
SM 2091, 2-7 HP Tecumseh Engine Service 
Manual. These are available through the 
normal JOHN DEERE Service Manual channels 



RM ENG 4 




4wM£WL 
■ 

S3 ■ ,jm>?i*W., 






Wg W W j^SSSSjjjfe. 



• 8 



********************* 






CLEANING SHROUDS AND FINS: 

It is important to keep the shrouding 
and fins free of grass and debris to 
maintain proper cooling of the engine. 
Remove the shrouding with starter as- 
sembled, gas tank and use compressed 
air to clean hard to get at areas. 
Cover gas line when cleaning fins. 

When reassembling the shrouding with 
starter attached, be sure the nylon 
guide in the starter is centered on the 
crankshaft. 



RM ENG 5 








*'Jk&- y„; 




fifck r4| 






" -' - " ilT* 








i 30k At* 





^ 



********************* 



- 5 - 



SECTION 20 
ENGINE 3 



ENGINE REMOVAL: 

Set the parking brake and raise the 
rider up on the rear stand. 

Loosen the belt guides on the engine 
output sheave. 

Remove the 3/8" cap screw in the center 
of the output sheave. Remove sheave 
and disconnect mower drive belt. 

Remove the transmission drive belt from 
the engine sheave. 



RM ENG 6 




Set the rider back down on its wheels 
and remove the (4) bolts holding the 
engine in place. 

Disconnect the safety start wires and 
throttle control cable. 

Remove the gas tank by pulling straight 
up and cover gas line to prevent con- 
tamination. 

CAUTION: Gas will leak out of tank as 
there is no shut-off valve. 



********************* 

RM ENG 7 



Turn the engine counter clockwise one 
quarter turn and remove from the rider 

Refer to SM 2091, 2-7 HP Tecumseh En- 
gine Service Manual for engine service 
procedures . 

Reverse the removal procedure for in- 
stallation of the engine. 



********************* 

70 ENG 13 





********************* 






- 6 - 



SECTION 20 
ENGINE 4 



THROTTLE CABLE INSTALLATION: 

Place the control lever in the high- 
speed position. 

Be sure that the control cover screws 
in the slotted holes on the left side 
of the control cover plate, are loose. 

Align the carburetor control lever as 
shown, so that the hole in the crook of 
the control lever is in alignment with 
the slot in the carburetor control cov- 
er. This is the high-speed position. 
Any movement of the control lever to the 
right begins to close the choke. 

Place a 3/32" alignment pin through 
control cover slot, choke lever, and 
choke operating arm. 

This will align the control cover with 
the choke operating lever and choke 
lever itself. Tighten the cover screws. 
Then, install control cable in carbure- 
tor control lever. Tighten clamp on 
control cable and remove alignment pin. 

The alignment pin used was cut from a 
standard wire coat hanger. 

*********** 



RM ENG 8 




•&&&■&•&•&&&■& 



RECOIL STARTER DISASSEMBLY: 

Disconnect safety start wires and re- 
move (4) bolts holding the starter as- 
sembly to the flywheel shrouding. 

Remove starter assembly. 



RM ENG 9 




********************* 



- 7 - 



SECTION 20 
ENGINE 5 



Pull out starter rope and tie a slip 
knot in the rope outside of the housing. 

Untie the knot on the end of the rope 
and remove metal retainer, handle, washer 
and safety start assembly. 



RM ENG 10 



********************* 







Untie slip knot and allow spring to 
unwind slowly, using your thumb as a 
brake. 

Removal of the retainer screw will al- 
low complete disassembly of the starter. 
Note the position of the starter dog 
and starter spring. 



RM ENG 11 




********************* 



The recoil spring has a retainer, which 
can be removed by turning as shown. 



RM ENG 12 




********************* 















SECTION 20 
ENGINE 6 



When reassembling, grease the center 
post and recoil spring lightly. In- 
stall the recoil spring retainer and 
lock tabs in place. 



RM ENG 13 




AAA****************** 



Install the starter dog, starter dog 
return spring and brake spring as shown. 



RM ENG 14 




********************* 



Reassemble retainer and tighten retainer 
screw 45-55 inch pounds. 



RM ENG 15 




********************* 



^ 



Hold starter as shown, using the thumb 
as a brake to retain the pulley as it 
is being wound. Insert a suitable tool 
in the knot opening in the pulley and 
wind until tight. Allow the pulley to 
to unwind only sufficiently so that the 
knot opening is positioned as shown. 



RM ENG 11 



9 - 




SECTION 20 
ENGINE 7 

Insert the rope as shown and seat the 
knot in the opening in the pulley. 
Tie a slip knot on the outside of the 
starter housing, so that the safety 
start bracket, washer, handle and re- 
tainer may be reinstalled. 

Test by pulling the rope. Action should 
be smooth, the starter dog should emerge 
quickly and the rope should retract com- 
pletely, if it is of the correct length. 

********************* 



10 



SECTION 20 
ENGINE 8 



rN 






ENGINE TROUBLE SHOOTING 



ENGINE FAILS TO START 

A. Clutch and mower pedals not In pro- 
per starting position. 

B. Carburetor not adjusted properly. 

C. Throttle lever not set properly. 

D. Spark plug wire loose or discon- 
nected. 

E. Spark plug improperly gapped. 

ENGINE STOPS WHEN PEDALS ARE ENGAGED 

Rope starter not retracted to hold neu- 
tral switch arm against engine. 

On Electric Start 56 Riders, Key is in 
"RUN" position instead of "OPERATE'.' 

HARD STARTING 

A. Faulty Ignition. 

Check for spark by removing the 
spark plug and grounding the plug 
to the cylinder head. Crank the 
engine and observe the spark. If 
no spark, check: 

1. Spark plug gap is incorrect. 

2. Spark plug electrodes are pitted 
or fouled. Replace plug. 

3. Breaker point gap is incorrect 
or breaker points are worn or 
pitted. 

4. Faulty magneto. 

B. Faulty Carburetion. 

1. Gasoline may not be getting to 
the carburetor because fuel line 
may be plugged. Clean fuel tank 
and fuel line. 

2. Carburetor may be dirty or out of 
adjustment. 



ENGINE MISSING UNDER LOAD 

A. Check spark plug for proper gap - 
.030. 

B. Check for lean fuel mixture. Ad- 
just carburetor high speed screw. 
See Fuel Section. 

C. Check for dirty (fouled) spark plug 
or improper type plug. 

D. Pitted or worn breaker points should 
be replaced with a new set. 



BACKFIRING 

A. Check carburetor for lean fuel mix- 
ture. See Fuel Section. 

B. Stickly intake valve or improper 
ignition. 



KNOCKING 

A. Use only a quality grade of regular 
gasoline. 

B. Check engine for overheating. 

C. Check crankcase oil level. Fill to 
top of plug hole. 

D. Check carburetor for lean fuel mix- 
ture. See Fuel Section. 

E. Possible loose connecting rod, im- 
proper timing or excessive carbon 
in combustion chamber. 






11 



SECTION 20 
ENGINE 9 



ENGINE TROUBLE SHOOTING CONT. 



LOSS OF ENGINE POWER 



A. Overheating. 



1. 
2. 

3. 

4. 



Check and clean intake screen 
and engine shrouds. 
Check for use of premium gaso- 
line with high octane rating. 
Use regular gas only. 
Check carburetor for lean fuel 
mixture. 

Check oil for excessive or too 
little oil in engine crankcase. 
Crankcase is full when oil is 
at the top of the plug hole. 
Check breaker points for proper 
gap- 



A. 

B. 
C. 
D. 



ENGINE WILL NOT IDLE 

Check carburetor adjustments. See 

Fuel Section. 

Dirty carburetor. 

Check and set spark plug gap - .030. 

Check carburetor for air leaks in 

gasket. 

Possible leaky valves or faulty 

condenser. 









B. Dirty Air Filter. 

1. Check and clean air filter. 

C. Choke is Partly Closed When Operat- 
ing at Full Throttle. 

1. Make sure throttle choke control 
cable is properly adjusted. 






ENGINE OPERATING ERRATICALLY 
Check the following : 

A. Carburetor setting. 

B. Clogged fuel line. 

C. Water in fuel. Drain fuel and 
clean fuel line. 

D. Loose throttle cable. 

E. Loose spark plug wire. 

F. Air leaks in carburetor connections 
or gasket. 

G. Carburetor jet clogged. 

H. Fuel tank cap vent hole plugged. 









12 



SPECIFICATIONS: 

FUEL SYSTEM 

Type of Fuel Regular gasoline 

Fuel Tank 2 U.S. quarts 

AIR CLEANER 

Type AM 30900 dry filter 

Clean every 25 hours of service. 
Replace when dirty. 



SECTION 30 
FUEL SYSTEM 1 



^ 






^ 






ADJUSTING CARBURETOR: 

If the engine misses, backfires, surges 
or starts hard, carburetor adjustment 
may be required. 

Idle adjustment and high speed adjust- 
ment must be made at the same time as 
each affects the other. Adjust as fol- 
lows : 

1. Turn high speed adjusting screw 
clockwise until closed. Screw on 
the left on 55 and on the bottom 
for 56. Close finger tight only. 
Then open one complete turn. 

2. Turn idle adjusting screw clock- 
wise until closed. Screw on the 
right on 55 and in the center on 
56. Close finger tight only. 
Then open one and one-half turns . 

3. Start engine and raise throttle 
lever to the "run" position. 
Allow engine to warm up . 

4. Turn high-speed adjusting screw 1/8 
turn each time, forward or backward, 
until engine runs smoothly at full 
throttle. Keep screw position 
slightly on the rich side (open) for 
maximum power when moving tall or 
thick grass. 

5. Final idle adjustment should be 
made at an engine speed of 1200 to 
1700 rpm. Move throttle lever to 
lowered "Idle" position and turn 
idle adjusting screw 1/8 turn each 
time, forward and backward, until 
engine idles smoothly. 



RM FS 1 




13 



SECTION 30 
FUEL SYSTEM 2 



Raise throttle lever quickly to 
check for uniform acceleration. 
If engine misses, gas-air mixture 
is too lean. Turn high speed 
adjusting screw counterclockwise 
until positive acceleration can be 
obtained. If excess exhaust smoke 
is noticed, mixture is too rich. 
Readjust idle screw, if necessary 
until good balance is achieved and 
engine idles smoothly. The top 
screw adjusts the speed at which the 
engine idles. This is factory 
adjusted and will not normally 
require adjustment. 



************************* 



CARBURETOR SERVICE 



70 ENG 13 



The 55 Riding Mower is equipped with a 
diaphragm carburetor. The 56 is equipped 
with a float type. 

For complete service on the internal 
components of the carburetors, refer 
to SM 2091, 2-7 HP Tecumseh Engine Ser- 
vice Manual. 




********************* 



The fuel tank may be removed for easy 
access of other engine components. 
Lift straight up on tank to remove. 
Note retainer tabs holding tank to en- 
gine. 

CAUTION: Gas will leak out the tank 
as there is no shut-off valve. Be 
careful not to get dirt in the gas line 
and carburetor. 



RM FS 2 




* * * * 



******* 



****** 






14 



SECTION 40 
ELECTRICAL SYSTEM 
1 



SPECIFICATIONS: 



Ignition High Tension Flywheel Magneto 

Spark Plug Gap 0.030 in. 

Breaker Point Gap 0.020 in. 

Optional Electric Start (BM 15529) 56 only 

Requires battery, JOHN DEERE AM 30094, 24 AMP. Hr. 12 volt 

Includes Starter, Starter Switch, Wire Harness, External Battery Charger (AM32400) 



********************* 



^ 






WIRING DIAGRAM AND SAFETY START SYSTEM: 

Shown is the wiring diagram for the 55 
and 56 Riding Mowers. 

There is no charge circuit as the mowers 
are equipped with manual recoil starters, 



RM ELECT 1 



The 55 and 56 Riding Mowers are equipped 
with a safety start system. The safety 
start circuit is simply a grounding sys- 
tem connected to the engine magneto. 
There is a safety switch on the drive 
clutch-brake pedal, mower clutch pedal 

and recoil start mechanism. 

********************* 



p^„ 



/ 



y 



i 



Lpi 



If the engine is to start, the pedal 
safety switches must be "open" to pre- 
vent grounding of the magneto. Shown 
is a drawing of a closed and open safety 
switch. Note when the switch is closed, 
the magneto is grounded. The "open" 
condition is obtained at the drive 
clutch-brake pedal by setting the park- 
ing brake. The mower clutch switch is 
"open" when the pedal is in the disen- 
gaged position. 



RM ELECT 2 




********************* 



15 - 



SECTION 40 
ELECTRICAL SYSTEM 
2 



The engine switch is merely the connec- 
tion between the magneto and the ground- 
ing switches on the drive clutch-brake 
and mower clutch pedals. Pulling out 
on the recoil starter rope closes the 
engine switch. 

If the drive clutch-brake or mower clutch 
pedal is engaged, that switch will ground 
out the magneto and the engine will fail 
to start. 

When the drive clutch-brake and mower 
clutch pedals are disengaged, the pedal 
switches are open, the engine will start. 

With the recoil start rope retracted, 
the engine's neutral start switch is 
"open". This permits engagement of the 
drive clutch-brake or mower clutch pedals 
for normal operation without grounding 
the magneto and killing the engine. 

*************** 

The 56 Riding Mower has an electric 
start kit available. Shown is the wir- 
ing diagram after the kit has been in- 
stalled. 

The operation of the safety start system 
works in the same way as before with the 
addition of a key start switch. When 
the key switch is in the "run" position 
the connection between the engine magne- 
to and foot pedal safety switches is 
closed. Foot pedal engagement will kill 
the engine. 

When the key switch is in the "operate" 
position the circuit is open and the 
foot pedals can be engaged. 



RM ELECT 1 



^ 



b— 
»-™^ /"" 


_Lnl 


•/ 1 






TEKMINAL ' [ SAFETY STMT SWITCH ELECTRICAL 


fc 




— — J 






****** 



RM ] 


SLECT 3 








"j 


J 


— 1 


= 


I* 




•^ ^_^< 






_ ifh. 


— . 


S_ A^--- 






V 


™ ft 








HmS \„„, 


^sZ. 










-< 






**************** 



* * * * 



- 16 






If the engine does not start after a 
few tries, check the system in the fol- 
lowing sequence. 

Be sure the throttle control lever is 
in the choke position (for a cold en- 
gine) or run position (for a warm en- 
gine) for starting. 

Be sure the drive clutch-brake pedal is 
in the park position. 

Check to see that the mower clutch pedal 
is disengaged. 



SECTION 40 
ELECTRICAL SYSTEM 
3 



RM ELECT 4 




********************* 



If the pedals and controls are set pro- 
perly, check the throttle plate at the 
magneto connection to be sure that the 
magneto is not grounded out. 

The throttle cable may be out of adjust- 
ment, causing the magneto to be grounded 
in position on the control panel other 
than stop. 



************** 



RM ELECT 5 




" 






If the magneto connection checks O.K. , 

check the safety start wiring harness 

to see if there are any loose connections. 

Use an ohm meter to check the safety 
switches. 

Start with the switch at the drive clutch- 
brake pedal. Connect the ohm meter to 
the switch terminals . Move the drive 
clutch-brake pedal back and forth and 
observe the switch open and close on the 
ohm meter. If the switch does not open 
and close, be sure that the switch arm 
properly contacts the drive clutch-brake 
pedal. The bracket is adjustable. 

Replace the switch if defective, or pro- 
ceed to check the other switches. 



RM ELECT 6 




********************* 



- 17 



SECTION 40 
ELECTRICAL SYSTEM 
4 



Lock the drive clutch-brake pedal in 
the park position. 

Connect the ohm meter leads to the 
safety switch on the mower clutch pedal. 
Move pedal back and forth to observe the 
switch open and close on the ohm meter. 
Again, check adjustment of switch and 
proceed or replace switch as necessary. 



RM ELECT 




********************* 



With the drive clutch-brake pedal down 
and the mower clutch pedal up, connect 
the ohm meter to the safety switch on 
the recoil starter. Pull the starter 
rope to activate the switch and observe 
switch on the ohm meter. 



RM ELECT 8 




********************* 



On the 56 Rider with the optional elec- 
tric start, check the ignition switch 
with an ohm meter connected to the two 
small terminals. Switch the key from the 
run to operate position to observe the switch 
open and close. 



RM ELECT 9 




********************* 



- 18 



SECTION 40 
ELECTRICAL SYSTEM 



IGNITION SYSTEM: 

If the safety circuit checks O.K. , but 
the engine will not start, we should 
check the ignition spark at the spark 
plug. 

At this point we will assume that the 
fuel system is functioning properly. 
In a situation of cranking but not 
starting, carburetor, fuel tank and 
line should all be checked as they may 
be malfunctioning. 



KM ELECT 10 







The first check would be to remove the 
spark plug and crank the engine with 
the plug grounded as shown. If weak 
or no spark is produced, check the spark 
plug gap. Proper gap is .030. It may 
be necessary to install a new plug if 
the old plug is pitted or burned. Then 
re test by cranking engine. 



********************* 



If still no spark is produced, it will 
be necessary to remove the shrouding 
and flywheel to gain access to the ig- 
nition points. 

A strap wrench like the one shown is a 
handy tool for holding the flywheel 
while removing the nut on the crank- 
shaft. 



RM ELECT 11 




■kjcic&-kj< m k'k m k , k-k-k& , k i k-k , k i $: , k'k , k 



19 



SECTION 40 
ELECTRICAL SYSTEM 
6 



Apply a small amount of pressure with a 
bar as shown to help remove the flywheel. 
Never hit on the end of the crankshaft 
with a hammer as this may break crank- 
shaft. 



RM ELECT 


12 
























i»L 


'-"^"K 








Br Jk 


'< '. -0 




% 


f" * 


4 



********************* 






Now turn the crankshaft until the lobe 
causes the points to open at the widest 
point. Check the points to see if they 
are pitted or burned. The proper gap 
is .020. 

It is always a good policy to replace 
the condenser when the points are re- 
placed. A faulty condenser can ruin 
the points. 

Even though it was necessary to remove 
the top three head bolts to gain access 
to these electrical components, it is 
not necessary to replace the head gas- 
ket. 



RM ELECT 13 







********************* 



If the ignition points appear to be 
good, then we should check the ignition 
coil. Remove the coil by prying off the 
wire retainer and disconnecting the leads. 



RM ELECT 14 




********************* 






20 



SECTION 40 
ELECTRICAL SYSTEM 
8 









r> 



ENGINE TIMING: 

When short blocking the engine for any 
other service work which requires re- 
moval and replacement of the coil 
mounting core and plate assembly, it 
will be necessary to time the engine 
as follows: 

1. Remove the engine shrouding 
with recoil starter assembled 
and flywheel. 

2. Remove cylinder head and gas- 
ket. 

3. Turn the crankshaft until the 
high point of the ignition cam 
causes the points to open. 

Set the point gap .020. 

4. Turn crankshaft until the pis- 
ton reaches top-dead-center. 
Then turn the crankshaft counter- 
clockwise until the piston moves 
down .080/. 090 below top of cy- 
linder block surface. 

5. Loosen the two screws that hold 
core and plate assembly to the 
cylinder. Remove the leads from 
the point terminal when using ohm 
meter or flashlight tester as 
shown. 



RM ELECT 15 







Connect one tester lead to the point 
terminal and the other lead to a 
ground. 

Position the core and plate assembly 
so that ignition cam on crankshaft 
just begins to open breaker points. 
This breaks the continuity and 
will be shown on the tester. 
Tighten core and plate assembly 
mounting screw to retain adjust- 
ment. 

Reassemble engine. Be sure to 
install new cylinder head gasket 
when reassembling. Tighten head 
bolts to 140-200 in. lbs. 






********************* 



21 - 



SECTION 40 
ELECTRICAL SYSTEM 

7 



There are five tests for an ignition 
coil: 

1. Coil power test. 

2. Coil high speed test. 

3. Coil surface insulation 
test. 

4. Continuity test. 

5. Coil ground test. 

Make all of these tests according to 
the instructions and specifications, 
which came with your tester. If no 
tester is available, install a new coil 
and check to see if this will correct the 
spark problem. 



70 ELECT 19 




********************* 






When replacing points or ignition coil 
do not remove or loosen the core and 
plate assembly as this will throw the 
engine out of time. 



70 ELECT 20 




%t?%/' 


f^< 


s ■ sS 

yXVY 


\vk 




' -—3 n^PiK 


SEjjjj^EjW^ ^\ v N*rf jrfflt 



********************* 



22 



SPECIFICATIONS: 

Brakes 

Type Friction, pedal operated 

Parking Hand lock to foot brake 

Clutch V-belt 



SECTION 50 
POWER TRAIN 1 



Transmission 

Type Gear box 

Gear Selections/ 2 Forward, 1 Reverse 
Lubricant EP Lithium (AT 30408) 



Differential 
Lubricant 



Bevel Gear Axle Assy. 
EP Lithium (AT 30408) 









Travel Speeds (MPH) 

1st. Gear 55 & 56 2.5 MPH 

2nd. Gear 55 & 56 4.0 MPH 

Reverse 55 & 56 2.5 MPH 



REPLACING TRANSMISSION DRIVE BELT: 

Depress drive clutch-brake pedal and set 
parking brake. Raise rider up on the 
rear stand. Loosen belt guide on the 
engine output sheave. 

NOTE: Bend the guides to 1/16 to 1/8- 
inch clearance from the sheave when in- 
stalling new belt. 



RM MOW 2 




********************* 



Remove the mower from the rider in the 
following sequence. Remove the right 
rear lift pin, washer and quick pull 
pin. Remove the quick pull pin and washer 
from the lift rod and PTO engagement rod. 



RM MOW 3 




********************* 



23- 



SECTION 50 
POWER TRAIN 2 



Remove the front draft arm pins. 

CAUTION: Hold the mower with one hand 
to prevent it from falling. 



RM MOW 4 







Remove the idler sheave from clutch 
idler arm. 



********************* 

RM PT 1 






Bend belt guides on transmission input 
sheave away from sheave and remove belt. 

Remove belt from engine sheave. Install 
new belt in the reverse order. 

NOTE: Bend belt guides to 1/4-inch 
from the transmission input sheave when 
installing new belt. 







********************* 



DRIVE CHAIN REPLACEMENT: 

Raise rider up on rear stand. 

Remove the mower as explained before. 

Loosen chain idler and slide out of the 
way. 

Disconnect chain at spring clip and re- 
move drive chain. 

Replace chain by reversing removal pro- 
cedure . 



RM PT 2 




- 



********************* 






- 24 



SECTION 50 
POWER TRAIN 3 






n 






BRAKE ADJUSTMENT: 

Adjust parking lever so pedal is 1/4 to 
1/2 -inch above the footrest when the 
parking lever is locked. Adjust this 
distance by moving the nut on the ad- 
justable parking lever. 



RMPT 3 




********************* 



With the parking brake adjusted and in 
the locked position, adjust the nut on 
the rear of the brake rod so the brake 
rod spring is compressed 1/8 -inch. 
This is the distance between the spring 
holder and swivel. 

NOTE: It may be necessary to remove the 
pedestal when making this adjustment to 
be able to read the scale. 

Brake service work, such as brake pad 
or disc replacement may be performed 
without disassembly of the transmission. 

Remove the brake linkage and the 12 point 
cap screw holding the brake assembly to the 
transmission. Torque the cap screw 
275 in. lbs. when reassembling the brake. 



RMPT 4 




********************* 









TRANSMISSION REMOVAL: 

Remove the mower in the same sequence as 
for transmission drive belt replacement. 

Remove the clutch idler pulley and re- 
move the snap ring holding the trans- 
mission input sheave in place. Pull 
the input sheave off and remove the drive 
belt. 



************** 



RM PT 1 




25 - 



SECTION 50 
POWER TRAIN 4 



Remove the (4) bolts holding the pedestal 
to the frame and lift off the pedestal 
and seat assembly. 



RM PT 5 




********************* 



Remove the cotter key holding the ten- 
sion spring on the brake link. Remove 
quick pull pin from brake link connector 
and separate brake rod from transmission. 



RM PT 5A 




********************* 



Remove the (4) bolts holding the trans- 
mission to the frame. Lift the trans- 
mission from the frame. 

CAUTION: Do not lose the spacers on 
the lower two bolts. 



RM PT 6 




********************* 



26- 



SECTION 50 
POWER TRAIN 5 






TRANSMISSION DISASSEMBLY 

Place shift lever in the neutral posi- 
tion as shown. 

Remove 7 bolts in housing and lift 
cover off. 



RM PT 7 



1 
i 








********************* 






No. 1 is the Input Shaft Assembly. 

No. 2 The shaft with the large bevel 
gears is called the Intermediate Shaft 
Assembly. 

No. 3 The shaft with the disc brake is 
the Output Shaft. 



RM PT 8 





^^^99s^B^^^^^^^^m 


^^^^^whsmI 


9K||y;^ 




d^^K 




3^11 Jem 




JHJHL^HK» bi£* V ' 


/. IMPU1 


| - W[JmX!&r*. ' ' 


I. /!ITeRM£OlflTE, , %K<'P9PP , '*' 


||gf. OUTPUT 




Hkar&ff.- n:i., tr i!^ : .',MJ**11*irf5K .ism » Itf-SlS 



********************* 



To remove the Input Shaft remove the 
snap ring and spacer washer (s) on the 
outside of the transmission. 

Press the Input Shaft out of the lower 
housing to the inside as shown. 

Any other removal procedure on the In- 
put Shaft will damage the needle bearings. 

This will remove Input Shaft, Needle 
Bearings and Pinion Gear as an assembly. 

CAUTION: If the Input Shaft is not to 
be removed, do not wash lower housing 
in solvent as it will wash all the grease 
out of the needle bearings. 



RM PT 9 




********************* 



27 



SECTION 50 
POWER TRAIN 6 



To disassemble Input Shaft Assembly, 
remove snap ring holding pinion gear 
and press shaft out of the pinion gear. 
Remove woodruff key, thrust washer and 
needle bearings. 



RM PT 10 




********************* 



To disassemble the shift lever, shifter 
forks or cam assembly, remove the detent 
ball and springs first. This will re- 
lease the spring pressure on the cam 
plate and top cover plate. 

NOTE: It is not always necessary to 
disassemble the shifter assembly in the 
upper housing. 



RM PT 11 




Remove four screws holding cover plate. 
Lift off cover plate and shift lever. 
Cam plate may then be removed. 

Remove the shifter forks by removing the 
two shoulder screws on each fork. 



********************* 

RM PT 12 













********************* 



TRANSMISSION REASSEMBLY 

Install each shifter fork with two 
shoulder screws. The shifter fork must 
be able to travel the full distance of 
the shifter track. 

Torque shoulder screws 40-50 in. lbs. 



RM PT 13 



-28- 




********************* 



SECTION 50 
POWER TRAIN 7 






Grease the cam plate lightly and in- 
stall the cam plate. The cam plate must 
be able to travel the full distance of 
the cam track. 

Replace the shift lever. Grease the 
bottom of the cover plate lightly and 
install. The extended portion of the 
cover plate goes to the knob side of the 
shift lever. 

Install the four screws in the cover 
plate. Torque to 25-30 in. lbs. 



RM PT 14 







A******************** 



r> 






Install the detent balls and springs. 
Apply pressure when screwing detent 
cover in place. 

Unless pressure is applied against the 
balls and springs by the cover as shown, 
you may strip the threads in the alumi- 
num housing. 

Torque screw in cover 25-35 in. lbs. 



RM PT 15 




********************* 



Assemble input shaft as shown. Install 
(2) needle bearings, thrust washer and 
woodruff key on input shaft. 

Pinion gear has a pilot to start pinion 
over key. Press pinion in place on 
shaft. 

NOTE: When rebuilding a transmission 
in the original housing, use the same 
washers if possible. This will give 
accurate end play on all shaft assem- 
blies. If new washers are required, 
the end play should be .010 to .020 on 
shafts after assembly. 



RM PT 16 




********************* 






29 



SECTION 50 
POWER TRAIN 



Press input shaft assembly back into 
lower housing from the inside out. In- 
stall spacer washers and snap ring on 
input shaft on outside of transmission. 
Always reuse the same spacer washers 
if possible. Be sure input shaft turns 
freely in housing. 



********************* 



Assemble output shaft as shown. 

Press special key into shaft. Install 
parts on shaft in the following sequence. 
Work from right hand end of shaft first. 

1. Snap ring. 

2. Thrust washer. 

3. Brass Key on shaft. 

4. 28 T Spur gear, flat side out. 

5. Flanged bearing. 

6. Washer. 

7. 8 T Sprocket. 

8. Snap ring. 



RM PT 17 




Install the parts on the left hand end 
as follows : 



1. Clutch collar, flat side 
toward snap ring. 

2. 22 T Spur gear, without 
keyway. (Flat side out) 

3. Flanged bearing. 

4. Flat washer. 

5. Retaining ring. 

6. Brass woodruff key. 

7. Brake disc. 






********************* 






30 - 



SECTION 50 
POWER TRAIN 9 









Assemble intermediate shaft as shown. 

Press special woodruff key into shaft. 

Install parts on the shaft in the fol- 
lowing sequence. Work from the right 
hand end of the shaft first. 

1. Clutch collar (collar is 
reversible) 

2. Bevel gear, smooth side out. 

3. Washer. 

4. Woodruff key. 

5. 22 T Spur gear with keyway . 

6. Flanged bearing. 

7. Washer. 

8. Retaining ring. 



RM PT 18 




Install the parts on the left hand as 
follows : 

1. Bevel gear, spur side out. 

2. Flanged bearing. 

3. Washer. 

4. Retaining ring. 



********************* 



Install Output Shaft Assembly and In- 
termediate Shaft Assembly into lower 
transmission housing. Be sure brake 
pads are in place when installing out- 
put shaft. Do not allow grease to con- 
tact brake pads. 

Be sure to align clutch collars in cen- 
ter so the shifter fork grooves are in 
alignment. These two fork grooves in 
center of transmission will give neu- 
tral lever position. 

Set flange bearings so stops engage 
notches in the lower housing. 

Fill lower case half with grease. 
(EP Lithium AT 30408) 



RM PT 1 


9 






/ 




^_* 


~^ 




\%1 


ljKpI* 






K • ^K^n 















31 - 



SECTION 50 
POWER TRAIN 10 



RM PT 



Replace cover. Be sure lever is in neu- 
tral position. Torque seven case bolts, 
80-90 in. lbs. 

The washers on the Intermediate Shaft 
and the Output Shaft outside of the 
transmission housing, should be free to 
turn. They should not be tight. This 
will give .010 - .020 end play in these 
shafts. 



ANALYSIS : 

Bevel gear cracked or broken indicates 
shock load. 

Output bearing failure caused by high 
torque. 

Radius of shifter collars indicates 
signs of shifting on the go. 

DIFFERENTIAL ASSEMBLY REMOVAL: RM PT 

Remove the mower as explained for re- 
placing transmission drive belt. 

Remove both rear wheels by removing bolt 
with lock nut thru axle shaft. 

Remove wheels, spacer washers, and 
spacer on axle shaft. 



********************* 








Loosen chain tightener and lift chain 
off large sprocket to the inside of the 
differential. 

Remove the bolts holding the self- 
aligning bearings on the axle to the 
frame. (Two on each side.) 



RM PT 22 




********************* 
- 32- 






SECTION 50 
POWER TRAIN 11 






n 



Lift the differential assembly out as 
shown. Raise and pivot the right hand 
side out first. This will eliminate the 
need of removing the engine output 
sheave. 



RM PT 23 




********************* 



r 






DIFFERENTIAL DISASSEMBLY: 

Disassemble the differential by remov- 
ing the (4) thru bolts in the differ- 
ential. 

Remove the snap ring from the axle shaft 
to separate bevel gear thrust washer, 
axle shaft and housing half. 



RM PT 24 



ait*. 




REASSEMBLY: 



********************* 

RM PT 25 



Assemble pinion assembly as shown with 
washers to the outside. 







********************* 



- 33 



SECTION 50 
POWER TRAIN 12 



Begin assembling the differential with 
the long (right) axle shaft side. Re- 
assemble axle shaft in differential 
housing and install thrust washer, be- 
vel gear and snap ring. 

Fill housing half with EP Lithium 
grease (AT 30408) . 



RM PT 26 




A******************** 



Install (4) thru bolts in housing as 
shown and lay the pinion assembly in 
place. 

Pack both halves of the differential 
with grease. 



RM PT 27 








r 




^ 


* 








% 




Bn 




;:*%; 






********************* 



Assemble the short side of the differ- 
ential assembly and place over the (4) 
thru bolts. Note the left housing half 
bolt holes are tapped. Torque bolts 
19-22 ft. lbs. 

Place the large sprocket over the thru 
bolts and install nuts. Torque nuts 
to 10-13 ft. lbs. 



RM PT 28 




********************* 



Install self-aligning bearings on the 
axle shaft as shown, making sure the 
grease retainer dish fits inside the 
bearing. The bearings bolt to the 
outside of the frame and the grease 
zerks go to the bottom. 

Install the wheels on the axle with the 
valve stems to the inside. 

Reinstall mower by reversing the removal 
procedure. - 34 



RM PT 29 




****************** 



* * 









r* 






SECTION 70 
MISCELLANEOUS 1 



STEERING SHAFT REMOVAL: 

Remove the nuts holding the tie rods 
to the steering shaft. 



RM MISC 1 




****************** 



* * 



Remove the handlebars or steering 
wheel by driving out the groove pin. 
Pull shaft out the bottom of the rider. 



RM MISC 2 




********************* 



To reinstall shaft, push shaft in from the 
bottom. Be sure nylon bearings on 
top and bottom remain in place. Connect 
the tie rods back to the steering shaft. 



RM MISC 3 




********************* 






-35- 



SECTION 70 
MISCELLANEOUS 2 



THROTTLE CONTROL CABLES: 

Remove handlebars or steering wheel. 
Remove (3) screws holding the control 
quadrant in place. 



RM MISC 4 







********************* 















36 - 



SECTION 80 
MOWER 1 






^ 



n 









SPECIFICATIONS: 

55 Rider 26" Mower 

56 Rider 28" Mower 

There is a difference between "a profit 
on a sale and a profitable sale". 

Remember, a large number of problems can 
result from over application. 

MOWER OPERATION 

Engage the mower by depressing the large 
pedal (1) on the right hand side of the 
steering column. Disengage by depressing 
small pedal (2) on right hand side. 

The mower lift lever (3) is located in 
the front of the seat pedestal. Each 
notch in the quadrant adjusts the cutting 
height 1/2-inch. The range of cut is 1 
to 3-inches. 

When mowing in heavy, tall grass, start 
the mower in the raised position. Operate 
engine at full throttle (4) when mowing. 
Adjust the ground speed with the desired 
transmission speed. 

*********** 

MOWER REMOVAL 

Depress drive clutch-brake pedal and 
set parking brake. 

Raise rider up on the rear stand. Loosen 
all belt guides on the engine output sheave, 

NOTE: Bend the guides to adjust 1/16 to 
1/8-inch clearance from the sheave when 
installing new belt. 



RM MOW 1 




********* 

RM MOW 2 




*********** 

Remove the mower from the rider in the 
following sequence. Remove the right 
rear lift pin, washer and quick pull pin. 
Remove the quick pull pin and washer from 
the lift rod and mower clutch engagement 
rod. 



********** 

RM MOW 3 




********************* 

- 37 - 



SECTION 80 
MOWER 2 



Remove the front draft arm pins. 

CAUTION: Hold the mower with one hand 
to prevent it from falling. 

Install mower by reversing removal pro- 
cedure. 



RM MOW 4 




****** * ******* 

MOWER BELT REPLACEMENT 

Loosen belt (1) guides and turn away from 
sheave. 

NOTE: Belt guides are properly adjusted 
when they are 1/8 to 1/4-inch away from 
the sheave. 

Pull spring locking pin (2) and remove 
washer. Lift idler assembly (3) off 
pivot post. 

Remove idler sheave (4) from arm and 
remove belt. 

Install new belt in reverse order. Be 
sure belt is installed with back side 
against idler sheave. 



* * * 



* * * 



RM MOW 5 




***************** 



LEVELING MOWER 

Park the mower on a flat surface such as 
a sidewalk or concrete driveway. 

Disconnect the spark plug wire to prevent 
accidental starting. 

With the mower in the raised position, 
measure the distance of one blade tip 
from the ground. Rotate the blade 90 
degrees each time and measure distance 
at the front, rear and each side of the 
mower. When the mower is level, these 
measurements should be within 1/8-inch 
of being the same. 



RM MISC 6 




-J<r iV 4f ■£■ 



»£. -J- »»- J, 









38 - 



SECTION 80 
MOWER 3 



1. To adjust for side- to- side level, 
loosen bolt on right front draft arm, 
press down or raise mower deck until 
blade is level. Tighten nut firmly. 

2. To adjust for front- to-rear level, 
pull cotter pin in rod and remove rod 
from bracket. Turn rod into yoke to 
raise rear of mower, or out of yoke to 
lower rear of mower, as necessary to 
level mower. 

Mower removed for clarity. 



RM MOW 7 




^ 



********************* 









r> 



MOWER BRAKE ADJUSTMENT 

The mower brake is properly adjusted when 
the distance between the mower engagement 
and release pedal is 1 to 1 1/2 -inch. 

This will provide proper braking to the 
mower belt. 



RM MOW 8 




********************* 



To arrive at the 1 to 1-1/2-inch adjust- 
ment, adjust the locking collar on the 
mower clutch brake rod. 



RM MOW 9 




********************* 



39 



SECTION 80 
MOWER 4 



s 






MOWING TIPS 

Pick up all rocks, glass, sticks, toys 
and other objects that may cause per- 
sonal injury or damage to the mower. 

Cutting grass at 1 1/2 or 2 -inches is 
satisfactory for most turf grasses. This 
will leave sufficient leaf area to give 
a neat appearing lawn. 

Mow often enough so that approximately 
1/3 of the leaf growth is removed at 
each cutting. This promotes dense growth 
which helps shade out weedy grasses. 

Cutting less often produces dense clip- 
pings which should be removed. 

When mowing dense, tall grass, it may 
be desirable to mow only a partial swath 
for efficient mowing. 

Mow with the left side of the mower next 
to bordering objects and areas to dis- 
charge clippings away from fences, flower 
beds, sidewalks, driveways, etc. Use 
first gear range for slow ground speed. 
To reduce speed further, lower throttle 
to 3/4 or 1/2 setting. 



RM MOW 10 







^ 



"This has been our two cents worth." 






********************* 



^ 



40